Comprehensive Mathematical Model for Simulating Electroslag Remelting
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ELECTROSLAG remelting (ESR) has been widely used to produce high-quality steel and alloys due to its ability to improve cleanness, macrostructure, distribution, and size of carbide particles and to its mechanical properties. The amount, dimension, and distribution of nonmetallic inclusion are one of the most important indices of the cleanliness of steel. Removing inclusions mainly occurs at the tip of the electrode due to the absorption and dissolution of inclusions in liquid slag.[1] A lot of factors affect the removal of nonmetallic inclusions including slag, remelting rate, input power, steel grade, and so on. But full contact of liquid slag and molten steel is the most important prerequisite. Three stages including droplet formation, dripping, and interaction between liquid slag and molten steel influence the sufficient contact between slag and metal. Droplet formation and its mass transfer in liquid slag play an important role in the inclusions’ removal. However, it is difficult to observe and obtain the droplet size under a real remelting environment. This is why no known experiments about the droplet formation are YAN-WU DONG, Associate Professor, ZHOU-HUA JIANG, Professor, JIN-XI FAN, Graduate Student, and YU-LONG CAO, DONG HOU, and HAI-BO CAO, Ph.D. Candidates, are with the School of Materials and Metallurgy, Northeastern University, Shenyang 110819, Liaoning, P.R. China. Contact e-mail: dongyw@ smm.neu.edu.cn Manuscript submitted October 26, 2014. Article published online January 4, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS B
reported for an industrial-scale electroslag remelting process.[2] Some physical models similar to the ESR process have been established to investigate the formation of droplets. Low-melting temperature metals have been used as electrodes; meanwhile, a solution of LiCl-KCl, NaOH, or NaCl has been used as slag. An oscilloscope is used to detect the occurrence of a droplet departure in conventional nontransparent slag by monitoring the curve of the voltage, and then dripping frequency can be obtained during the process.[3,4] Although these physical experiments can be used to study the formation and detachment of droplets, they do not represent real conditions of the ESR process. In recent years, mathematical models have been widely used to simulate the ESR process. Mathematical simulation is a faster and better time-saving method for investigating the ESR process. In addition, it is feasible because a lot of real parameters of material about ESR can be applied in simulation, which will improve the precision of the model. In addition, the effect of droplets on liquid slag and a molten steel pool is necessarily considered in the ESR process. The average droplet diameter should be obtained for calculating the process mentioned earlier.[5–8] However, we cannot attain the droplet information during ESR immediately. Kharicha et al.[9–11] developed some models to study droplet behavior in the ESR process by using a multiphase flow method. Ru¨ckert et al.[12] established a model to invest
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